Air tables for making mattress toppers and related method

ABSTRACT

A mattress topper for fitting to a mattress may include a lower layer, a side layer configured to extend down along a side of the mattress, and an upper layer overlaying the lower layer and at least partially disposed between the lower layer and the side layer. The mattress topper may also include a seam including threads and extending along peripheral edges of the lower layer and the upper layer and extending through the lower layer, upper layer, and side layer, the lower layer and side layer bearing the threads of the seam. An air table may include a top panel including a plurality of vents extending through the top panel. A method of making a mattress topper with an air table may include lifting the mattress topper with the air table while performing sewing procedures on the mattress topper.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.15/063,192, filed Mar. 7, 2016, the disclosure of which is herebyincorporated herein in its entirety by this reference.

TECHNICAL FIELD

This disclosure relates generally to mattress toppers and air tables formaking mattress toppers. This disclosure further relates to methods ofmaking mattress toppers with an air table.

BACKGROUND

Mattress toppers are often used to add cushion and/or support tomattresses. The mattress toppers often appear bulky and out of place.Furthermore, stress placed on the mattress topper during use (e.g.,while sleeping on the mattress topper) can cause seams of the mattresstopper to tear through the fabrics of the mattress topper, thus,shortening a lifetime of the mattress topper.

Making mattress toppers (e.g., performing sewing functions on a mattresstopper) can be difficult because the mattress toppers are often heavyand difficult to maneuver while sewing. Sewing tables used to makemattress toppers often require multiple people to maneuver a mattresstopper while sewing the mattress topper, and a weight of the mattresstopper can often cause difficulty and/or mistakes while sewing themattress topper.

BRIEF SUMMARY

Some embodiments of the present disclosure include a mattress topper forfitting to a mattress. The mattress topper may include a lower layer, aside layer configured to extend down along a side of the mattress, anupper layer overlaying the lower layer and at least partially disposedbetween the lower layer and the side layer, and a seam including threadsextending along peripheral edges of the lower layer and the upper layerand extending through the lower layer, upper layer, and side layer. Thelower layer and side layer of the mattress topper may bear the threadsof the seam.

Some embodiments of the present disclosure include a mattress topper forfitting to a mattress. The mattress topper may include a lower layer, anupper layer overlaying the lower layer, and a side layer comprising astrip of material and extending along a peripheral edge of the lowerlayer and the upper layer and at least partially overlaying the upperlayer. The side layer may be configured to extend down along a side ofthe mattress. The mattress topper may further include a seam includingthreads and connecting the lower layer, upper layer, and side layertogether. The side layer and the lower layer may bear the threads of theseam.

Some embodiments of the present disclosure include an air table formaking a mattress topper. The air table may include a top panel having aplurality of vents extending from a bottom surface of the top panel to atop surface of the top panel, a bottom panel disposed beneath the toppanel, wherein a top surface of the bottom panel is at leastsubstantially parallel to the top surface of the top panel, at least onesidewall extending along peripheral edges of the top panel and bottompanel and extending between the top panel and the bottom panel, and anair chamber defined between the top panel and the bottom panel and bythe at least one sidewall. The air table may further include at leastone air intake hole extending from a bottom surface of the bottom panelto the top surface of the bottom panel, and at least one air supplyconnected to the bottom panel and at least substantially aligned withthe at least one air intake hole, the at least one air supply configuredto blow air into an air chamber of the air table through the at leastone air intake hole and to blow air out of the air chamber of the airtable through the plurality of vents of the top panel.

Some embodiments of the present disclosure include a method of making amattress topper with an air table. The method may include disposing themattress topper on a top surface of the top panel of the air table, thetop panel including a plurality of vents extending therethrough, causingair to blow through plurality of vents of the top panel of the airtable, and causing the mattress topper to lift up relative to the topsurface of the top panel of the air table.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed understanding of the present disclosure, reference shouldbe made to the following detailed description, taken in conjunction withthe accompanying drawings, in which like elements have generally beendesignated with like numerals, and wherein:

FIG. 1 is a simplified and schematically illustrated partialcross-sectional side view of a mattress topper according to anembodiment of the present disclosure;

FIG. 2 is a simplified and schematically illustrated partialcross-sectional side view of a mattress topper according to anotherembodiment of the present disclosure;

FIG. 3 is a simplified and schematically illustrated partialcross-sectional side view of the mattress topper of FIG. 2 fitted on amattress;

FIG. 4 is a simplified perspective view of an air table for makingmattress toppers according to an embodiment of the present disclosure;

FIG. 5 is a simplified partial cross-sectional side view of the airtable of FIG. 4;

FIG. 6 is a simplified and schematically illustrated partialcross-sectional side view of an air table having a mattress topperdisposed thereon according to an embodiment of the present disclosure;

FIG. 7 is a simplified top view of an air table for making mattresstoppers according to another embodiment of the present disclosure;

FIG. 8 is a simplified perspective view of an air table for makingmattress toppers according to another embodiment of the presentdisclosure;

FIG. 9 is a simplified perspective view of an insertable portion of theair table having a sewing machine for sewing with the air table of FIG.8 according to an embodiment of the present disclosure; and

FIG. 10 is a flowchart of a process for making a mattress topper with anair table according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

The illustrations presented herein are not actual views of any mattresstopper, air table, or any component thereof, but are merely idealizedrepresentations, which are employed to describe the present invention.

As used herein, any relational term, such as “first,” “second,”“adjacent,” “top,” “bottom,” “lower,” “upper,” “middle,” “beneath,”“above,” “below,” etc., is used for clarity and convenience inunderstanding the disclosure and accompanying drawings, and does notconnote or depend on any specific preference or order, except where thecontext clearly indicates otherwise. For example, these terms may referto an orientation of elements of a mattress topper when disposed on amattress in a conventional manner. Furthermore, these terms may refer toan orientation of elements of an air table when assembled on a groundsurface.

As used herein, the term “substantially” in reference to a givenparameter, property, or condition means and includes to a degree thatone skilled in the art would understand that the given parameter,property, or condition is met with a small degree of variance, such aswithin acceptable manufacturing tolerances. For example, a parameterthat is substantially met may be at least about 90% met, at least about95% met, or even at least about 99% met.

Some embodiments of the present disclosure include a mattress topper forfitting to a mattress and adding cushion and/or support to the mattress.The mattress topper may include a lower layer, an upper layer, and aside layer. The lower and side layers may include woven fabrics and theupper layer may include a knitted fabric. The lower and upper layers maybe at least generally a size of a top of a mattress upon which themattress topper is to be fitted. Furthermore, the lower and upper layersmay rest on the top of the mattress when the mattress topper is fittedto a mattress. The side layer may include at least one strip of materialand may be shaped similar to a bed skirt or fitted sheet. In otherwords, the side layer may be sized and shaped to extend down along aside of the mattress from the lower layer and the upper layer. The lowerlayer, upper layer, and side layer may be connected together with aseam. The seam may be sewn along a peripheral edge of the lower andupper layers. The seam may include a plurality of threads, and thethreads of the seam may be borne by the side layer and the lower layer.The side layer and the lower layer may serve to protect the upper layerof the mattress topper. The side layer may be sized and shaped to extendfrom the seam and then fold back on itself to extend down along the sideof the mattress.

Some embodiments of the present disclosure include a mattress topperhaving a deformable support layer disposed between the lower layer andthe upper layer. The deformable layer may include a gel material.

Some embodiments of the present disclosure include an air table formaking a mattress topper. The air table may be configured to providelift to the mattress topper while the mattress topper is being sewn. Forexample, the air table may be configured to lift up the mattress topperwith air. The air table may include a top structure that includes a toppanel having a plurality of vents extending therethrough. The air tablemay also include an air supply to blow air through the vents.Accordingly, the mattress topper may be placed above the plurality ofvents of the top panel of the top structure of the air table, and airmay be caused to blow through the plurality of vents to provide lift tothe mattress topper. In other words, the mattress topper may be causedto “float” (e.g., hover) above a top surface of the top panel due to theair being blown through the plurality of vents.

FIG. 1 is a partial cross-sectional view of a mattress topper 100according to an embodiment of the present disclosure. Some features ofthe mattress topper 100 of FIG. 1 may be exaggerated and/simplified tobetter show features of the mattress topper 100 and for clarity. Themattress topper 100 may be disposable on (e.g., fitted to) a mattress toadd cushion (e.g., softness, comfort, pressure relief, etc.) and/orsupport (e.g., body support, spinal alignment, etc.) to the mattress.The mattress topper 100 may include a lower layer 102, an upper layer104, and a side layer 106. The lower layer 102, the upper layer 104, andthe side layer 106 may be connected together (e.g., sewn together) witha seam 108. The seam 108 may include a plurality of threads 110, and theseam 108 may extend along and proximate to a peripheral edge of themattress topper 100. At the seam 108, the side layer 106 may be orientedadjacent to the upper layer 104, which in turn, is oriented adjacent tothe lower layer 102. In other words, the upper layer 104 may be disposedbetween the side layer 106 and the lower layer 102 at the seam 108 ofthe mattress topper 100.

The lower layer 102 and the upper layer 104 of the mattress topper 100may be generally the same size as a top of a mattress upon which themattress topper 100 is to be fitted. For example, the lower layer 102and the upper layer 104 may be generally the same size as a top of atwin, full, queen, king, or California king mattress depending on thesize of the mattress. The side layer 106 may be sized and shaped similarto a bed skirt or fitted sheet. For example, the side layer 106 mayinclude a strip of material sewn with the seam 108 to the outerperipheral edge of the upper and lower layers 104, 102. In other words,the side layer 106 may be sized and shaped to extend down from the upperlayer 104 and the lower layer 102 along a side of the mattress and to atleast substantially fully expose the upper layer 104. In someembodiments, the side layer 106 may be sized and shaped to extend alonga full height of the mattress and to be at least partially tucked underthe mattress. In some embodiments, the side layer 106 may include anelastic member 112 attached to the side layer 106 along an inner edge ofthe side layer 106 (e.g., an edge opposite the seam 108 and an edge thatwould be tucked under a mattress during use). The elastic member 112 mayhelp keep the mattress topper 100 fitted to the mattress. Alternatively,other means may be employed for this same purpose, such as a partiallysewn-in cord that can be tightened (cinched) and/or tied.

In some embodiments, the upper layer 104 may include a knitted fabricthat is relatively more prone to unraveling and to tearing and lessrobust relative to the side layer 106 and the lower layer 102, which mayinclude woven fabrics. Disposing the upper layer 104 (i.e., the moredelicate fabric) between the side layer 106 and the lower layer 102(i.e., the more robust fabrics) at the seam 108 and seaming the sidelayer 106, the upper layer 104, and the lower layer 102 together withthe seam 108 in such an orientation may provide a more robust seam 108and connection between the layers 102, 104, 106. In some embodiments,the lower layer 102 and the side layer 106 may bear the threads 110 ofthe seam 108. In other words, threads 110 of the seam 108 may bearagainst the fabrics of the lower layer 102 and the side layer 106, andthe threads 110 of the seam 108 may simply pass through the fabric ofthe upper layer 104. Furthermore, due to the fabric of the side layer106 and the lower layer 102 being woven, the side and lower layers 106,102 may be less likely to let the seam 108 tear through the side layer106 and the lower layer 102. Furthermore, having the side and lowerlayers 106, 102 bear the threads 110 of the seam 108 may reduce stressplaced on the upper layer 104 by the seam 108 during use of (i.e., whilesleeping on) the mattress topper 100. Accordingly, the side layer 106and the lower layer 102 may serve to protect the more delicate upperlayer 104, and a lifetime of the mattress topper 100 may be extended.Furthermore, the seam 108 may be more robust (e.g., durable, strong,effective, etc.) than if the threads 110 of the seam 108 were to bearagainst the upper layer 104. Also, during sewing procedures, sewing theseam 108 in the orientation described above, avoids any need to closethe seam 108 prior to trimming (e.g., cutting) the upper layer 104(i.e., knitted layer).

As discussed above, the mattress topper 100 may be fitted to a mattress,and the side layer 106 of the mattress topper 100 may be folded back onthe seam 108 and oriented to extend along the sides of a mattress. Theside layer 106 may serve to secure the mattress topper 100 to themattress and to at least partially hold the mattress topper 100 in placerelative to the mattress.

FIG. 2 shows a partial cross-sectional view of a mattress topper 100according to another embodiment of the present disclosure. Some featuresof the mattress topper 100 of FIG. 2 may be exaggerated and/orsimplified to better show features of the mattress topper 100 and forclarity. The mattress topper 100 may be similar to the mattress topper100 of the FIG. 1 and may include a deformable support layer 202disposed between the upper layer 104 and the lower layer 102 of themattress topper 100.

In some embodiments, the deformable support layer 202 material mayinclude a hyper-elastic polymer. For example, the deformable supportlayer 202 may be formed entirely from a gel, or the deformable supportlayer 202 may have a composition comprising a gel and one or moreadditional non-gel materials. Such gels and gel compositions aredescribed in, for example, U.S. Pat. No. 5,749,111 titled “GelatinousCushions with Buckling Columns” and issued on May 12, 1998, U.S. Pat.No. 6,026,527 titled “Gelatinous Cushions with Buckling Columns” issuedFeb. 22, 2000, and U.S. Pat. No. 5,994,450 titled “Gelatinous Elastomerand Methods of Making and Using the Same and Articles Made Therefrom”issued on Nov. 30, 1999, each of which patents is incorporated in itsentirety herein by this reference. In one embodiment, the gel mayinclude an elastomeric gel comprising between about 15 to about 600parts plasticizer per 100 parts solid elastomer by weight. For example,in one embodiment, the gel may comprise KRATON® E1830 elastomer and awhite food grade mineral oil, such as CARNATION® oil. In anotherembodiment, the gel may comprise SEPTON® 4055 elastomer and a white foodgrade mineral oil. In additional embodiments, the gel may comprise apolyurethane-based gel, a silicone-based gel, and a PVC-based gel. Thedeformable support layer 202 may be a bare un-coated deformable supportlayer 202, or the deformable support layer 202 may be coated, coveredwith, adhered to, fused with, or integral with another material. Forexample, the deformable support layer 202 may include a cushion layersimilar to the cushion described in U.S. Pat. No. 8,932,692, to Pearce,issued Jan. 13, 2015.

The deformable support layer 202 may have a thickness within the rangeof about 0.5 inch (1.27 cm) to about 3.0 inches (7.62 cm). In someembodiments, the deformable support layer 202 may have a thickness ofabout 2.0 inches (5.08 cm).

In some embodiments, the lower layer 102 of the mattress topper 100 maycomprise a scrim fabric (e.g., a woven or non-woven fabric material) andportions of the deformable support layer 202 may seep through (e.g., bemelt-fused into, bleed through, push through, leak through, passthrough, etc.) the scrim fabric of the lower layer 102. For example,when the deformable support layer 202 includes a gel material, portionsof the gel material may be heat fused through the lower layer 102 of themattress topper 100. The portions of the deformable support layer 202that extend through the scrim fabric of the lower layer 102 may create anon-slip surface or reduced slip surface on a lower surface 204 of thelower layer 102 (e.g., surface that would contact a mattress) of themattress topper 100. The non-slip surface or reduced slip surfacecreated by the deformable support layer 202 may help the mattress topper100 stay in place relative to a mattress when fitted to a mattress.

Although the mattress topper 100 is described herein as including adeformable support layer 202, the disclosure is not so limited. Insteadof or in addition to the deformable support layer 202, the mattresstopper 100 may include one or more deformable layers of foam, felt, gel,air chambers, or other fibers (as a non-limiting example, polyesterbatting fill material).

When the mattress topper 100 includes the deformable support layer 202,the seam 108 of the mattress topper 100 may be separated from thedeformable support layer 202 by a distance D along a plane defined by abottom surface 206 of the deformable support layer 202 and in adirection perpendicular to a side of the deformable support layer 202facing the seam 108. In some embodiments, distance D may be within arange of about 0.25 inch (0.635 cm) to about 5.0 inches (12.70 cm), arange of about 0.25 inch (0.635 cm) to about 3.0 inches (7.62 cm), or arange of about 0.25 inch (0.635 cm) to about 1.50 inches (3.81 cm). Forexample, distance D may be about 0.50 inch (1.27 cm). The deformablesupport layer 202 may have a general rectangle shape (e.g., the generalshape of a mattress), and the seam 108 may be separated from each end(i.e., both longitudinal ends and lateral ends) of the deformablesupport layer 202 by distance D.

FIG. 3 shows a partial cross-sectional view of the mattress topper 100of FIG. 2 fitted on a mattress 302 and shows a drop down feature of themattress topper 100. Some features of the mattress topper 100 and themattress 302 of FIG. 3 may be exaggerated and/or simplified to bettershow features of the mattress topper 100 and the mattress 302 and forclarity. Referring to FIGS. 2 and 3 together, because the seam 108 ofthe mattress topper 100 is separated from the deformable support layer202 by distance D, the seam 108 may drop below a bottom surface 206 ofthe deformable support layer 202 when the mattress topper 100 is fittedto the mattress 302. In other words, the fabric of the upper layer 104and the fabric of the lower layer 102 may extend past a top 308 of themattress 302 and may extend at least some distance down a side of themattress 302. To facilitate description of the mattress topper 100 inthe present disclosure, the upper and lower layers 104, 102 extendingdown at least some distance along a side of the mattress 302 will bereferred to hereinafter as the “drop down feature.”

The drop down feature of the mattress topper 100 may help prevent a seamof the mattress 302 and the seam 108 of the mattress topper 100 frombeing immediately adjacent to (e.g., stacked on top of) each other. Bynot stacking the seams, the mattress topper 100 may avoid a bulgingappearance when fitted to a mattress 302. As a result, the drop downfeature of the mattress topper 100 may provide the mattress topper 100with a blended transition appearance when fitted to the mattress 302.Furthermore, the drop down feature may provide a more aestheticallypleasing appearance when fitted to a mattress 302. Moreover, bydistancing the seam 108 of the mattress topper 100 from a seam of themattress 302 (e.g., keeping the seam 108 of the mattress topper 100 fromstacking onto the seam of the mattress 302), less stress may be placedon the seam 108 when fitting the mattress topper 100 to the mattress 302and during use of (e.g., when sleeping on) the mattress topper 100.Reducing stress on the seam 108 of the mattress topper 100 may extend alife of the mattress topper 100.

FIG. 4 is a perspective view of an air table 400 that may be used whenmaking (e.g., sewing) the mattress toppers 100 of FIGS. 1-3 according toan embodiment of the present disclosure. Referring to FIGS. 3 and 4together, for example, the air table 400 may be used to at leastpartially lift up a mattress topper 100 with air (i.e., provide lift tothe mattress topper 100) to facilitate making the mattress topper 100.Mattress toppers 100 having the deformable support layer 202 can berelatively heavy, and because the deformable support layer 202 mayextend through the lower layer 102 of the mattress topper 100, themattress toppers 100 may be difficult to maneuver especially when suchextension of material is meant t create a non-slip or non-skid effect.Thus, lifting the mattress toppers 100 with air (e.g., causing themattress topper 100 to at least partially float or hover above the airtable 400) can help facilitate fabrication of the mattress toppers 100and, in particular, the sewing of the seam 108.

The air table 400 may include a top structure 402, a plurality of legs404, at least one air supply 406, and a plurality of vents 408. The topstructure 402 may include a top panel 410 and a bottom panel 412. Theplurality of vents 408 may extend through the top panel 410 of the topstructure 402. The plurality of legs 404 may extend from the bottompanel 412 of the top structure 402 and, when the air table 400 is in useand assembled, may rest on a ground surface. In some embodiments, the atleast one air supply 406 may be disposed beneath the top structure 402of the air table 400 and may be attachable to the bottom panel 412 ofthe top structure 402. In other embodiments, the at least one air supply406 may be attachable to a sidewall or the top panel 410 of the airtable 400. Regardless, the at least one air supply 406 may be orientedto blow air into the top structure 402 of the air table 400. In someembodiments, the at least one air supply 406 may include a centrifugalblower.

In some embodiments, the plurality of vents 408 may be formed (e.g.,oriented) in the top panel 410 of the top structure 402 in a pattern. Inother words, the plurality of vents 408 may be oriented in a patternwith respect to one another. For example, in some embodiments, theplurality of vents 408 may be oriented in a one-inch grid pattern. Inother words, the plurality of vents 408 may be spaced apart from oneanother by about 1.0 inch (2.54 cm) along a length of the air table 400and along a width of the air table 400. In other embodiments, theplurality of vents 408 may be oriented in a grid pattern and may bespaced apart from each other by about 1.0 inch (2.54 cm) to about 10inches (25.4 cm). In other embodiments, the plurality of vents 408 maybe oriented in circles, concentric rectangles, or any other pattern.

In some embodiments, the air table 400 may have a longitudinal lengthwithin a range of about 250 inches (635 cm) to about 350 inches (889cm). For example, the air table 400 may have a longitudinal length ofabout 288 inches (731.5 cm). In some embodiments, the air table 400 mayhave a lateral width within a range of about 50 inches (127 cm) to about150 inches (381 cm). For example, the air table 400 may have a lateralwidth of about 96 inches (243.8 cm). As a non-limiting example, the airtable 400 may accommodate articles at least a size of a California Kingsize mattress topper. However, although specific dimensions are providedin the present disclosure, one of ordinary skill in the art wouldreadily recognize that a size of the air table 400 could be adjusted toaccommodate different sizes of articles that may be made with the airtable 400.

The top surface of the top panel 410 of the top structure 402 may belocated between about 34 inches (86.4 cm) and about 42 inches (106.7 cm)from a ground surface when the air table 400 is assembled. A top surface(e.g., working surface) at this height may provide a comfortable workingsurface for seated operators of the air table 400. In other words, theheight of the top surface may reduce fatigue a user may experience whenusing the air table 400.

When the air table 400 is operating, the at least one air supply 406 mayblow air into the top structure 402 of the air table 400 and the air mayescape (e.g., be blown) through the plurality of vents 408. The airblown out of the plurality of vents 408 may provide a lift for liftingarticles placed on the air table 400, the lift provided by a thin sheetof flowing air between the article placed on the air table 400 and thetop surface of the air table 400.

In some embodiments, the air table 400 may be mountable to a groundsurface with fasteners coupled with the plurality of legs 404 of the airtable 400. Mounting the air table 400 to a ground surface may provideadditional stability and predictability when operating the air table400.

FIG. 5 is a partial cross-sectional side view of the top structure 402of the air table 400 of FIG. 4. The top structure 402 may include thetop panel 410, the bottom panel 412, an air chamber 414, the pluralityof vents 408, at least one air intake hole 416, a sidewall 418, and atleast one support member 420. The top panel 410 may be oriented abovethe bottom panel 412 and may at least partially define the air chamber414 between the top panel 410 and the bottom panel 412. The sidewall 418may extend along outer peripheral edges of the top panel 410 and bottompanel 412 and may extend between the top panel 410 and the bottom panel412. The sidewall 418 may also at least partially define the air chamber414.

The plurality of vents 408 may extend through the top panel 410 of thetop structure 402. For example, the plurality of vents 408 may extendfrom a bottom surface 422 of the top panel 410 to the top surface 424 ofthe top panel 410. Each vent 408 of the plurality of vents 408 mayinclude a large section 426 and a small section 428. The large section426 of a respective vent 408 may have a larger diameter than a diameterof the small section 428 of the respective vent 408. The large section426 may extend from the bottom surface 422 of the top panel 410 (i.e.,surface facing the air chamber 414) and may extend partially through thetop panel 410 but may not extend completely through the top panel 410.For example, the large section 426 of a respective vent 408 may extendhalfway or over halfway through the top panel 410. The small section 428may extend from the large section 426 of the vent 408 and may extendthrough a remainder of the top panel 410 and through a top surface 424of the top panel 410.

The large sections 426 of the plurality of vents 408 may have diameterswithin a range of about 0.125 inch (0.318 cm) to about 1.50 inches (3.81cm). For example, in some embodiments, the large sections 426 may havediameters of about 0.50 inch (1.27 cm). The small sections 428 of theplurality of vents 408 may have diameters within a range of about 0.02inch (0.05 cm) to about 0.25 inch (0.635 cm). For example, in someembodiments, the small sections 428 may have diameters of about 0.0625inch (0.16 cm).

The large sections 426 of the plurality of vents 408 may havelongitudinal lengths within a range of about 0.02 inch (0.05 cm) toabout 3.0 inches (7.6 cm). For example, the large sections 426 of theplurality of vents 408 may have longitudinal lengths of about 1.0 inch(2.54 cm). The small sections 428 of the plurality of vents 408 may havelongitudinal lengths within a range of about 0.02 inch (0.05 cm) toabout 3.0 inches (7.6 cm).

The large sections 426 and the small sections 428 of the plurality ofvents 408 may enable a velocity (e.g., speed) of the air travelingthrough the plurality of vents 408 to be increased. For example, the airtraveling through the plurality of vents 408 may experience a Venturieffect, which is known in the art, where a velocity of a fluid flowsthrough a constricted section (i.e., small sections 428 of the pluralityof vents 408) of a pathway increase. Increasing a velocity of the airtraveling through the plurality of vents 408 may provide increased liftnear the top surface 424 of the top panel 410 of the air table 400. Forexample, when wanting to provide lift to an object, increasing airvelocity is often more effective than increasing a pressure of the air.Thus, by increasing a velocity of the air traveling through theplurality of vents 408 of the air table 400, the lift provided by theair (i.e., force placed against an object disposed on the top surface424 of the top panel 410 of the air table 400 by the air) is increased.In some embodiments, the diameters of the large sections 426 and thesmall sections 428 may be selected to provide a certain amount of lift(e.g., force) for a selected amount of air flow.

Having the small sections 428 of the plurality of vents 408 extendthrough only a portion of the top panel 410 (e.g., reducing a length ofthe small sections 428) instead of the completely through the top panel410 (i.e., by including the large sections 426), may reduce a resistancethat air experiences when traveling through the plurality of vents 408.As a result, a flow rate of the air may be less affected by theresistance, which reduces a load on the at least one air supply 406 tomaintain a selected flow rate, which saves on costs and makes the airtable 400 more efficient.

In some embodiments, a longitudinal axis 430 of each vent 408 of theplurality of vents 408 may be orthogonal to the top surface 424 of thetop panel 410 of the top structure 402. In other embodiments, an acuteangle may be defined between the longitudinal axis 430 of each vent 408of the plurality of vents 408 and the top surface 424 of the top panel410 of the top structure 402.

The top and bottom panels 410, 412 may have thicknesses within a rangeof about 0.02 inch (0.05 cm) to about 3.0 inches (7.6 cm). For example,the top and bottom panels 410, 412 may thicknesses of about 0.75 inch(1.91 cm). In some embodiments, the top and bottom panels 410, 412 mayinclude one or more of a medium-density fiberboard (“MDF”) material,particle board, plywood, wood, or a polymer material.

In some embodiments, the at least one air intake hole 416 may extendthrough the bottom panel 412 of the top structure 402 of the air table400. In other embodiments, the at least one air intake hole 416 mayextend through a sidewall 418 or the top panel 410 of the air table 400.In some embodiments, the at least one air intake hole 416 may begenerally centered between lateral and longitudinal sides of the airtable 400. In some embodiments, the air table 400 may include two ormore air intake holes 416, and the two or more air intake holes 416 maybe generally evenly spaced apart to give at least generally consistentairflow throughout the air chamber 414 of the air table 400. The atleast one air supply 406 may be aligned with (e.g., connected to the airtable 400 at) the at least one air intake hole 416 and may provide airto the air chamber 414 of the air table 400 through the at least one airintake hole 416.

The at least one support member 420, if any, may be disposed in the airchamber 414 of the air table 400, may extend between the top panel 410and the bottom panel 412, and may support the top panel 410. In someembodiments, the at least one support member 420 may include at leastone post made of a structural material such as, for example, metal,wood, or plastic. In some embodiments, the at least one support member420 may include two or more support members 420, and the two or moresupport members 420 may be at least substantially evenly distributed(e.g., spaced apart from one another) within the air chamber 414 of theair table 400 and between the top panel 410 and the bottom panel 412.However, the air table 400 may not include too many support members 420.In other words, the air table 400 may not include a number of supportmembers 420 that would detrimentally reduce airflow to the plurality ofvents 408 of any portion of the air table 400.

FIG. 6 is a partial cross-sectional side view of the air table 400 ofFIG. 5 having the mattress topper 100 of FIG. 3 disposed thereon. Someelements of FIG. 6 may be exaggerated and/or simplified to better showelements of the air table 400 and the mattress topper 100 and forclarity. As discussed above, the air table 400 may provide lift underthe mattress topper 100 to help an operator maneuver the mattress topper100 while sewing the mattress topper 100 (e.g., sewing the seam 108).

In some embodiments, the mattress topper 100 may be at leastsubstantially permeable and would likely not be lifted by the air table400 if placed in direct contact with the air table 400. Thus, to providelift to the mattress topper 100, a substrate panel 432 may be placedbetween the mattress topper 100 and the air table 400. The substratepanel 432 may be at least substantially “airtight” (e.g., may not let asignificant amount of air pass therethrough). For example, the substratepanel 432 may include a panel of a polymer material, cardboard,STYROFOAM®, metal, fabric, or any other airtight or low-air permeablematerial.

During use, air blown through the plurality of vents 408 of the airtable 400 may push against the substrate panel 432 and may exert a forceon the substrate panel 432. The force exerted on the substrate panel 432may cause the substrate panel 432 to lift up (e.g., hover, float, etc.)relative to the top surface 424 of the top panel 410 of the air table400 such that at least some air is between the substrate panel 432 andthe top surface 424 of the top panel 410 of the air table 400. Bylifting the substrate panel 432, the air table 400 may also lift amattress topper 100 that is placed on the substrate panel 432.

In some embodiments, the substrate panel 432 may be smaller in size thana mattress topper 100 when viewed from a plane defined by the topsurface 424 of the air table 400 (e.g., a plane that is perpendicular tothe plane defined by FIG. 6). In other words, the substrate panel 432may not extend past or to the peripheral edge of the mattress topper 100when the mattress topper 100 is disposed on the substrate panel 432. Thesmaller size of the substrate panel 432 may allow portions of themattress topper 100 to brush against (e.g., touch) the air table 400when the substrate panel 432 and mattress topper 100 are lifted by theair table 400. In other words, portions of the mattress topper 100 mayhang over an outer peripheral edge of the substrate panel 432 and maydrop onto the air table 400. Having portions of the mattress topper 100touch the air table 400 may help to reduce and/or prevent unintentionalmovement of the mattress topper 100. For example, having portions of themattress topper 100 touch the air table 400 may prevent the mattresstopper 100 from moving unintentionally while being lifted by the airtable 400.

Reducing and/or preventing unintentional movement of the mattress topper100 may provide greater control of the mattress topper 100 whenmaneuvering the mattress topper 100 on the air table 400. Greatercontrol of the mattress topper 100 when maneuvering the mattress topper100 may lead to fewer mistakes while making the mattress topper 100 andmay increase safety for an operator when sewing the mattress topper 100.

Moreover, the smaller size of the substrate panel 432 may help to keepat least some distance between the substrate panel 432 and the seam 108of the mattress topper 100. The distance between the substrate panel 432and the seam 108 of the mattress topper 100 may keep the substrate panel432 from interfering with the seam 108 of the mattress topper 100 whenan operator is sewing the seam 108. For example, while the mattresstopper 100 is lifted by the air table 400, an operator may sew the seam108 of the mattress topper 100.

In some embodiments, multiple substrate panels 432 may be used insteadof a single substrate panel 432. For example, when sewing a relativelylarge article, such as a king sized mattress topper 100, multiplesubstrate panels 432 may be used to lift different portions of the kingsized mattress topper 100.

Referring to FIGS. 5 and 6 together, depending on the size of an articlebeing sewn, an amount of lift (e.g., a force being applied to thesubstrate panel 432 by the air being blown through the plurality ofvents 408) may be adjusted by adjusting how much air is being blown intothe air chamber 414 of the air table 400 by the at least one air supply406. For example, when sewing a relatively heavy article, such as amattress topper 100 comprising a gel layer, an amount of lift may beincreased, and when sewing a relatively light article, such as amattress topper 100 comprising a foam layer (and not a gel layer), anamount of lift may be decreased.

FIG. 7 is a top view of an air table 400 having a top panel 410 removedto better show internal elements of the air table 400. In someembodiments, the air table 400 may include one or more divider members434. The divider members 434 may be disposed within the air chamber 414(FIG. 5) of the air table 400 and may divide the air chamber 414 intotwo or more air chamber portions 414 a, 414 b, 414 c, etc. For example,the divider members 434 may divide the air chamber 414 into a first airchamber 414 a portion and a second air chamber 414 b portion. In suchembodiments, each air chamber portion 414 a, 416 b may include arespected air intake hole 416 and an air supply 406.

By dividing the air chamber 414 into two or more air chamber portions414 a, 414 b, 414 c, an operator may select which portions of the airtable 400 the operator wishes to activate (e.g., turn on) when making anarticle. By being able to select which portions of an air table 400 theuser wants to use, it may allow the user to use only portions of the airtable 400 necessary for making the article. As a result, less energy(e.g., electricity) may be required when making smaller articles, whichmay lead to cost savings and increased efficiencies.

Furthermore, by dividing the air chamber 414 into two or more airchamber portions 414 a, 414 b, 414 c, an operator may customize amountsof lift provided at different portions of the air table 400. Forexample, some portions of the air table 400 may be set to provide morelift than other portions of the air table 400.

FIG. 8 is a perspective view of an air table 400 according to anotherembodiment of the present disclosure. In some embodiments, the air table400 may include a cutout portion 436 extending from a side of the airtable 400 and toward a center of the air table 400. FIG. 9 is a partialperspective view of the air table 400 of FIG. 8 and an insertableportion 438 having a sewing machine 440 attached thereto. Referring toFIGS. 8 and 9 together, the insertable portion 438 may be sized andshaped to fit within the cutout portion 436 of the air table 400.

The cutout portion 436 of the air table 400 may enable a sewing machine440 to be disposed within a boundary defined by an outer peripheral edgeof the air table 400. Having the sewing machine 440 disposed within theboundary of the air table 400, may allow the sewing machine 440 toperform sewing procedures on an article (e.g., sewing the seam 108 on amattress topper 100) without having the article extend beyond theboundary of the air table 400 (i.e., not being supported and/or liftedby the air table 400).

Moreover, the cutout portion 436 may allow sewing machines 440 andrespective insertable portions 438 used in conjunction with the airtable 400 to be readily and quickly exchanged. As a result, sewingmachines 440 for performing different sewing procedures (e.g., differentsewing stitches) may be readily exchanged at a given air table 400 sothat different sewing procedures can be performed on an article withoutmoving that article from air table 400 to air table 400.

FIG. 10 shows a flowchart of a process 1000 of sewing an article on anair table 400. Referring to FIGS. 3-6 and 10 together, the process mayinclude disposing an at least substantially airtight or alow-air-permeable substrate panel 432 on an air table 400, asrepresented in act 1002. The substrate panel 432 may include one or moreof a polymer material, cardboard, STYROFOAM®, metal, fabric, or anyother airtight or low-air-permeable material. An article to be sewn maybe disposed upon the substrate panel 432 such that the substrate panel432 is disposed between the article and the substrate panel 432, asrepresented in act 1004. In some embodiments, the article may include amattress topper 100 such as the mattress toppers 100 described in regardto FIGS. 1-3.

An operator may cause the air table 400 to blow (e.g., expel) airthrough a plurality of vents 408 extending through a top surface 424 ofair table 400 underneath the substrate panel 432, as represented in act1006. The air blown through the plurality of vents 408 may exert a forceon the substrate panel 432 and/or article to be sewn. The substratepanel 432 and/or article may be caused to be lifted relative to (e.g.,to float above) the air table 400 by the air blowing through theplurality of vents 408, as represented in act 1008. An operator maymaneuver the article relative to the air table 400 while the article islifted relative to the air table 400, as represented in act 1010. Anoperator may perform sewing procedures on the article while the articleis lifted relative to the air table 400, as represented in act 1012. Insome embodiments, the sewing procedures may include sewing a seam 108along a peripheral edge of the article (e.g., mattress topper 100), asrepresented in act 1014.

The embodiments of the disclosure described above and illustrated in theaccompanying drawings do not limit the scope of the disclosure, which isencompassed by the scope of the appended claims and their legalequivalents. Any equivalent embodiments are within the scope of thisdisclosure. Indeed, various modifications of the disclosure, in additionto those shown and described herein, such as alternative usefulcombinations of the elements described, will become apparent to thoseskilled in the art from the description. Such modifications andembodiments also fall within the scope of the appended claims andequivalents.

What is claimed is:
 1. An air table configured and operable for precisepositioning making a mattress topper, comprising: a top panel comprisinga plurality of vents extending from a bottom surface of the top panel toa top surface of the top panel that defines an exterior of the airtable, each vent of the plurality of vents having a longitudinal axisthat is orthogonal to the top surface of the top panel and opening tothe exterior of the air table; a bottom panel disposed beneath the toppanel, wherein a top surface of the bottom panel is at leastsubstantially parallel to the top surface of the top panel; at least onesidewall extending along peripheral edges of the top panel and bottompanel and extending between the top panel and the bottom panel; an airchamber defined between the top panel and the bottom panel and by the atleast one sidewall; at least one air intake hole extending from anexterior of the air table to the air chamber of the air table; and atleast one air supply connected to the at least one air intake hole, theat least one air supply configured to blow air into the air chamber ofthe air table through the at least one air intake hole and to blow airout of the air chamber of the air table through the plurality of ventsof the top panel.
 2. The air table of claim 1, wherein the at least oneair intake hole of the air table comprises a plurality of air intakeholes and the at least one air supply comprises a plurality of airsupplies.
 3. The air table of claim 1, wherein the air table furthercomprises at least one divider member extending between the top paneland the bottom panel and dividing the air chamber into a first airchamber portion and a second air chamber portion.
 4. The air table ofclaim 1, wherein each vent of the plurality of vents of the air tablecomprises: a large section extending from the bottom surface of the toppanel and partially through the top panel; and a small section extendingfrom the large section and to the top surface of the top panel, adiameter of the large section being larger than a diameter of the smallsection.
 5. The air table of claim 4, wherein the diameter of the largesection is within a range of about 0.125 inch (0.318 cm) to about 1.5inches (3.81 cm) and wherein the diameter of the small section is withina range of about 0.02 inch (0.05 cm) to about 0.25 inch (0.635 cm). 6.The air table of claim 5, wherein the vents of the plurality of ventsare oriented in a grid pattern.
 7. The air table of claim 4, wherein thelarge section of each vent of the plurality of vents has a longitudinallength with a range of about 0.02 inch (0.05 cm) to about 3.0 inches(7.6 cm), and wherein the small section of each vent of the plurality ofvents has a longitudinal length with a range of about 0.02 inch (0.05cm) to about 3.0 inches (7.6 cm).
 8. The air table of claim 5, whereinthe vents of the plurality of vents of the air table are oriented in agrid pattern.